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Home >> Chevrolet >> 2004 >> Venture Base, Van Cargo Extended >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Disc Brake System) >> Repair Instructions >> Brake Caliper Overhaul - Front >> Removal Procedure
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Removal Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Monte Carlo and 2004 Chevrolet Impala. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.
  1. Remove the front brake caliper from the vehicle. Refer to Brake Caliper Replacement - Front .
    2. CAUTION: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury.
    NOTE: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged.
  2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole.
    3. Fig 1: Removing Brake Caliper Piston Using Low Pressure Compressed Air
    GM698626Courtesy of GENERAL MOTORS CORP.
  3. Using a small wooden or plastic tool, remove the caliper dust boot seal (2) from the seal counterbore in the caliper (1) and discard the boot seal.
  4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal.
  5. Remove the bleeder valve (5) and cap (6) from the caliper (1).
    6. Fig 2: Exploded View Of Brake Caliper
    GM105258Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Do not use abrasives to clean the brake caliper piston.
  6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent.
  7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air.
  8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
  9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
  10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly.
  11. Inspect the caliper piston for cracks, scoring, and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist.
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